Heating element assembly

ABSTRACT

An assembly for supporting an open coil heating element is provided. The assembly includes an elongated arm to which is secured a plurality of cross-members. The cross-members each have cutouts therein which extend from an opening to an edge. A capping member is provided for each cross-member with each capping member having cutouts therein alinged with its associated cross-member cutouts. The heating coil is secured in position by a plurality of insulating bushings each of which is captured in part by the surfaces of the cross-member defining a cutout and in part by the surfaces of the capping member defining the associated cutout. The capping members are secured to the crossmembers thereby rigidly securing the bushings and thus the heating coil in position.

United States Patent [191 Osterkorn et al.

1 1 HEATING ELEMENT ASSEMBLY [73] Assignee: Fedders Corporation, Edison, NJ. [22] Filed: Aug. 24, 1973 [21] Appl. No.: 391,265

[451 May 21, 1974 Forsher 338/317 X Hackman et a1 219/532 Primary Examiner-Velodymyr Y. Mayewsky Attorney, Agent, or Firm-Ryder, McAulay, Fields, Fisher & Goldstein [5 7 ABSTRACT An assembly for supporting an open coil heating element is provided. The assembly includes an elongated arm to which is secured a plurality of cross-members. The cross-members each have cutouts therein which extend from an opening to an edge. A capping member is provided for each cross-member with each capping member having cutouts therein alinged with its associated cross-member cutouts. The heating coil is secured in position by a plurality of insulating bushings each of which is captured in part by the surfaces of the cross-member defining a cutout and in part by the surfaces of the capping member defining the associated cutout. The capping members are secured to the cross-members thereby rigidly securing the bushings and thus the heating coil in position.

2 Claims, 2 Drawing Figures HEATING ELEMENT ASSEMBLY BACKGROUND OF THE INVENTION The present invention relates generally to heating coils and in particular to an improved construction for supporting an open coil heating element.

Open coil heating elements are widely used and find many applications in the heating and air conditioning fields. For example, such coils may be used as heaters in conjunction with air conditioning units to provide all-weather temperature control.

The heating coil comprises a high resistance wire, such as Nichrome, which when a current passes through, rapidly becomes red-hot. The amount of heat generated is proportional to the length of the Nichrome wire and it is common practice to coil the wire and then loop the coil back and forth to reduce the overall space requirements necessary to contain a wire of the length required for a particular application. Oftentimes, more than one coil is utilized.

Heretofore, various schemes have been suggested and utilized for the purpose of supporting the heating coil. Typical of the prior art is US. Pat. No. 3,641,312 which discloses a frame including a plurality of crossmembers which support insulator bushings through which the heating coil passes. Each of the bushings passes through a hole in the cross-member and is held in position by a plurality of radial tongues arranged about the periphery of the hole. The bushings must individually be positioned and locked in position to insure safe and proper operation. It is not until all the bushings are in position that the Nichrome wire can be passed through the bushings and the heating assembly completed. While this arrangement produces satisfactory results, it is relatively time consuming to assemble and hence expensive from a manufacturing standpoint.

It is the principal object of the present invention to provide an improved open coil heating element assem-.

bly which insures the safe separation of the various sections of the heating coil and at the same time is relatively fast, simple and inexpensive to manufacture and assemble.

SUMMARY OF THE INVENTION The above and other beneficial objects and advantages are attained in accordance with the present invention by providing an assembly for supporting an open coil heating element comprising an elongated arm to which a plurality of cross-members are secured. The cross-members each have at least one cutout therein extending from an opening to an edge. Associated with each cross-member is a capping member which also contains at least one cutout extending from an opening to an edge, the capping member cutouts being aligned with those of its associated cross-member. The assembly further includes a plurality of insulator bushings each of which is seated in and partially captured by a cross-member opening and partially captured by the associated capping member opening. Means are provided for securing the capping members to their associated cross-members whereby to firmly secure the bushings in position.

BRIEF DESCRIPTION OF THE DRAWINGS In the accompanying drawing:

FIG. 1 is an exploded perspective view of a heating element assembly in accordance with the present invention;

FIG. 2 is a fragmentary sectional view detailing the manner in which the heating assembly components are secured to one another.

DETAILED DESCRlPTlON OF THE PREFERRED EMBODIMENT Reference is now made to the drawings wherein the heating element assembly 10 of the present invention is illustrated. The assembly 10 comprises a series of elongated arms 12 (only one of which is illustrated) to which a plurality of cross-members 14 are secured. As illustrated, each cross-member 14 extends generally transverse to arm 12 and is secured to the arm by a screw 16 which passes through the arm to engage a tab 18 formed in the cross-member. The tabs are cut from the cross-member and bent perpendicular to'the crossmember longitudinal axis so that they abut arm 12.

Each cross-member 14 is provided with a series of cutouts 20 therein arranged in a row. The cutouts each comprise generally semi-circular openings 22 which extend from opposite ends of a diameter to the upper edge 24 of the cross-member along straight sides 26. The diameter of the semi-circular opening 22 and hence the space between the opposed straight sides of the cutout is approximately equal to the diameter of the center portion of an associated insulating bushing28.

Bushing 28 comprises a disc formed of a suitable insulating material such as porcelain having a groove extending about its circumference. The bushing may thus be considered as a central disc 30 to which end disc portions 32 are affixed. The diameter of each semicircular opening 22 of the cross-members is slightly larger than that of the associated bushing central portion 30 but not as large as that of the outer portions 32 so that the bushing groove can be positioned within the cutout 20 whereafter the bottom and sides of the bushing are captured in position by the surfaces of the crossmember defining the straight sides of the cutout as well as the semi-circular opening.

The heating assembly 10 further comprises a plurality of capping members 34 each associated with one of the cross-members 14. Each capping member 34 contains a plurality of cutouts 36 therein aligned with the cutouts 20 of the cross-member. As with the crossmembers, the capping member cutoutseach comprise a generally semi-circular opening 38 which extends from opposite ends of a diameter to the bottom edge 40 of the capping member along straight sides 41. The diameter of openings 38 in the capping member are substantially the same as those of the cross-member openings 20. Further, the capping member openings are positioned to line up with the cross-member openings when the capping member is in position in an assembled heating assembly as will be described.

Each capping member 34 includes a top edge 42 which is bent through two turns to define a channel 44 extending along the full length of the capping member. The width of channel 44 is substantially equal to the thickness of the cross-member. Thus, as shown in the drawings, the top edge of the cross-member is designed to be captured by channel 44 and thus secured in place over the cross-member. To further secure each cross-member to its associated capping member, the

cross-members are provided with tabs 46 which extend upwardly from the cross-member top edge 24 through slots 48 in the channel. When the tabs are bent as illustrated in FIG. 2, they provide a firm lock to secure the capping member in position.

As stated, the capping member cutouts are positioned to align with the cutouts of their associated cross-members. Thus, when each capping member is in position over its associated cross-member and a bush ing is seated within the cross-member cutout, the capping member opening 38 captures a portion of the bushing in the same manner as the cross-member. in this way, both the cross-member and capping member each capture a portion of the associated bushing and firmly hold it in position. The assembly is locked when the capping member is locked to the cross-member.

The bushings 28 are each provided with a central opening passing therethrough. A heating coil 50, such as a coiled length of Nichrome wire, passes through the bushings from cross-member to cross-member back and forth along the length of the assembly in lines generally parallel to arm 12, as shown in the drawing. The ends 52 of the heating coil are fitted with suitable terminals (not shown) to permit connection to an electrical power supply. The bushings serve to maintain the alignment of the coil and prevent contact of the coil with adjacent sections of the coil or with other parts of the assembly which may thus be formed of any convenient material such as sheet metal.

The heating element assembly is assembled by positioning bushings 28 in the cross-member openings prior to fitting the capping members in position. For ease of assembly, the heating coil 50 may be passed through the bushings prior to positioning them on the crossmember. After the bushings are all in position, the capping members are then placed over the cross-members to capture the top of the bushings in the manner previously described whereafter the tabs are bent to lock the bushings in place. In this manner, the capping members are locked to the cross-members with the bushings firmly secured in both the cross-member and capping member openings.

Thus, in accordance with the above, the aforementioned objects are effectively attained.

We claim:

1. An assembly for supporting an open coil heating element, said assembly comprising:

a. a generally strip-like configuration and at least two cross-member having at least one cutout therein, in a single row, extending from an opening to the top edge;

b. a capping member having at least two cutout therein extending from an opening to the bottom edge positioned over said cross-member, the top edge of said capping member being rolled over and directed downwardly whereby to define a channel, and said cross-member top edge is captured in and secured in position by said channel;

c. an insulator bushing seated in and partially captured by each said cross-member opening and partially captured by said capping member opening, said bushing having an opening therein for said heating coil to pass through; and

(1. means for securing said capping member to said cross-member with said bushing captured therebetween.

2. The assembly in accordance with claim 1 further comprising a plurality of spaced openings provided in said cross-member each extending to said crossmember top edge; an equal plurality of openings in said capping member, said capping member openings being aligned with said cross-member openings and extending to said capping member bottom edge; tab means extending from said cross-member top edge between two adjacent cross-member cutouts; and slot means in said capping member channel between the two adjacent capping member cutouts corresponding to the crossmember cutouts, said tab being capturable in said slot whereby to firmly secure said capping member to said cross-member.

- UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No- 3.812.322 Dated May 21, 1974 LQbarlaa-p iiaupw w nfletjla It is certified that error appears in the above-identified patent andn that said Letters Patent are hereby corrected as shown below:

At Col..4, line 7, "a generally strip-like configuration and at least two cross-member having at least one cutout therein" should be -at least one cross-member having a generally strip-like configuration and at least two cutouts therein,--;

at Col. 4, line 21, "captured by said capping member" should be --captured by each said capping member'- Signed and sealed this 8th day of October 1974.

(SEAL) Attest:

MCCOY M. GIBSON JR. c. MARSHALL DANN Attesting Officer Commissioner of Patents USCOMM-DC 60376-P69 fir U.S GOVERNMENT PRINTING OFFICE: 1909 0-366-331 =ORM PO-105O (10-69) o UNITED STATES PATE T OFFICE I 7 CERTIFICATE OF CORRECTION Patent No- 3.812.322 Dated May 21, 1974 t flsl ghgrles Louis Oste'rkorn et al It is oertifiedjthaterror appears in the above-identified patent and othat said Letters Patent are hereby corrected as shown below:

At Col. ,4; line 7, "a generally striplike configuration and at least two cross-member having at least one cutout therein" should he -at least one cross-member having a generally strip-like configuration and at least two cutouts therein, C Q

at Col 4, line 21, ."captured by said capping niember" should be --captured by each said capping member-'- Signed and sealed this 8th day of October 1974.

(SEAL) Attest; I

MCCOY M. GIBSON JR. 0. MARSHALL DANN Attesting Officer 7 Commissioner of Patents PC4050 uscoMM Dc 60376-P69 U,S. GOVERNMENT PRINTING OFFICE: I", D ni-334 

1. An assembly for supporting an open coil heating element, said assembly comprising: a. a generally strip-like configuration and at least two crossmember having at least one cutout therein, in a single row, extending from an opening to the top edge; b. a capping member having at least two cutout therein extending from an opening to the bottom edge positioned over said crossmember, the top edge of said capping member being rolled over and directed downwardly whereby to define a channel, and said cross-member top edge is captured in and secured in position by said channel; c. an insulator bushing seated in and partially captured by each said cross-member opening and partially captured by said capping member opening, said bushing having an opening therein for said heating coil to pass through; and d. means for securing said capping member to said cross-member with said bushing captured therebetween.
 2. The assembly in accordance with claim 1 further comprising a plurality of spaced openings provided in said cross-member each extending to said cross-member top edge; an equal plurality of openings in said capping member, said capping member openings being aligned with said cross-member openings and extending to said capping member bottom edge; tab means extending from said cross-member top edge between two adjacent cross-member cutouts; and slot means in said capping member channel between the two adjacent capping member cutouts corresponding to the cross-member cutouts, said tab being capturable in said slot whereby to firmly secure said capping member to said cross-member. 